CN108781013B

CN108781013B - Insulating member and stator

Info

Publication number: CN108781013B
Application number: CN201780019346.8A
Authority: CN
Inventors: 畔柳彻; 梶田効; 保母贵彦
Original assignee: Hayashikogyosyo Co ltd; Aisin AW Co Ltd
Current assignee: Hayashikogyosyo Co ltd; Aisin AW Co Ltd
Priority date: 2016-03-31
Filing date: 2017-03-30
Publication date: 2020-11-03
Anticipated expiration: 2037-03-30
Also published as: US10811921B2; US20190207459A1; JP6599550B2; CN108781013A; DE112017000601T5; WO2017170895A1; JPWO2017170895A1

Abstract

The invention provides an insulating member and a stator, wherein a first insulating sheet includes a folded portion provided at a portion corresponding to a bent portion of a coil and folded a plurality of times in a manner that the first insulating sheet is laminated.

Description

Insulating member and stator

Technical Field

The invention relates to an insulating member and a stator.

Background

Conventionally, a stator provided with an insulating member is known. Such a stator is disclosed in, for example, japanese patent No. 2941164.

Japanese patent No. 2941164 discloses a stator including three-phase windings (coils) arranged in slots of a stator core. In this stator, the winding is formed by winding a conductor wire a plurality of times. Further, insulating paper is provided between coil ends (portions of the windings that protrude from the end surfaces of the stator core in the direction of the rotation axis) of the windings of the respective phases. The insulating paper is configured to insulate coil ends of the phase windings from each other.

Patent document 1: japanese patent No. 2941164

However, in japanese patent No. 2941164, an insulating paper is provided between coil ends of each phase winding, and on the other hand, the shape of the coil is relatively largely deformed when the coil is formed (deformed), and therefore, a problem is considered that the insulating paper (insulating member) provided between the coil ends is broken. Therefore, there is a problem that insulation between the coils may not be ensured.

Disclosure of Invention

The present invention has been made to solve the above problems, and an object of the present invention is to provide an insulating member and a stator that can prevent the possibility that insulation between coils cannot be secured due to damage of the insulating member.

In order to achieve the above object, an insulating member according to a first aspect of the present invention includes an insulating member main body including a first insulating sheet provided in a ring shape so as to cover a coil, the coil including: the first insulating sheet includes a folded portion provided at a portion corresponding to a bent portion of the coil, and is formed by folding the first insulating sheet a plurality of times in a laminated manner.

In the insulating member according to the first aspect of the present invention, as described above, the first insulating sheet includes the folded-back portion provided at a portion corresponding to the bent portion of the coil and folded back a plurality of times so as to be laminated. Accordingly, the folded portion on which the first insulating sheet is laminated expands (unfolds) following deformation of the bent portion of the coil at the time of molding, and therefore, breakage of the insulating member due to deformation of the coil can be prevented. As a result, it is possible to prevent the insulating property between the coils from being unable to be ensured due to the breakage of the insulating member.

A stator according to a second aspect of the present invention includes: a stator core; a coil disposed on the stator core, the coil including: a slot housing portion housed in a slot of the stator core, and a coil end portion protruding from an end surface of the stator core in a rotation axis direction; and an insulating member provided in a ring shape so as to cover the coil, the insulating member including a folded portion provided at a portion corresponding to the bent portion of the coil and folded a plurality of times so as to be laminated.

In the stator according to the second aspect of the present invention, as described above, the insulating member includes the folded-back portion provided at a portion corresponding to the bent portion of the coil and folded back a plurality of times so as to be laminated. Accordingly, the folded portion on which the first insulating sheet is laminated expands (unfolds) following deformation of the bent portion of the coil at the time of molding, and therefore, breakage of the insulating member due to deformation of the coil can be prevented. As a result, it is possible to provide a stator in which it is possible to prevent the insulation between the coils from being unable to be ensured due to the breakage of the insulating member.

According to the present invention, as described above, it is possible to prevent the possibility that the insulation between the coils cannot be ensured due to the breakage of the insulating member.

Drawings

Fig. 1 is a plan view of a rotating electric machine (stator) according to first to third embodiments of the present invention.

Fig. 2 is a diagram showing coils according to first to third embodiments of the present invention.

Fig. 3 is a diagram showing first coils (second coils) according to first to third embodiments of the present invention.

Fig. 4 is a diagram showing third coils according to the first to third embodiments of the present invention.

Fig. 5 is a diagram showing a coil and an insulating member according to a first embodiment of the present invention.

Fig. 6 is a cross-sectional view taken along line 200-200 of fig. 5.

Fig. 7 is a partially enlarged view of fig. 5 (in the vicinity of the boundary between the slot-housed portion and the coil end portion).

Fig. 8 is a partially enlarged view of fig. 5 (near the top of the coil end).

Fig. 9 is a view showing an approximately U-shaped insulating member.

Fig. 10 is an enlarged cross-sectional view of a coil disposed in a stator.

Fig. 11 is a development view of an insulating member according to the first embodiment of the present invention.

Fig. 12 is a view showing a state in which the insulating member of fig. 11 is folded back (a state in which a folded-back portion is formed).

Fig. 13 is a side view of the insulating member of fig. 12.

Fig. 14 is a view showing a state in which the insulating member of fig. 12 is bent into a substantially U-shape.

Fig. 15 is a plan view of the bobbin.

Fig. 16 is a view showing a state in which the slot housing portion of the coil of fig. 5 is twisted.

Fig. 17 is a sectional view taken along line 300-300 of fig. 16.

Fig. 18 is a view showing a state in which coil ends of the coil of fig. 16 are molded (deformed).

Fig. 19 is a diagram showing a state in which coil end portions of coils disposed in a stator core are molded (deformed).

Fig. 20 is a diagram showing two insulating members (coils) arranged adjacent to each other.

Fig. 21 is a view showing an insulating member according to a second embodiment of the present invention.

Fig. 22 is a sectional view of an insulating member according to a second embodiment of the present invention.

Fig. 23 is a view showing a state after the insulating member is folded back (a state where a folded-back portion is formed).

Fig. 24 is a view showing a state in which the insulating member of fig. 23 is bent into a substantially U-shape.

Fig. 25 is a view showing a state in which an end portion of a substantially U-shaped insulating member is bent so as to cover a coil.

Fig. 26 is a view showing an insulating member according to a third embodiment of the present invention.

Fig. 27 is a view showing a state after the insulating member is folded back (a state where a folded-back portion is formed).

Fig. 28 is a view showing a state in which the insulating member of fig. 27 is bent into a substantially U-shape.

Fig. 29 is a view showing an insulating member (bent in a substantially U-shape) according to a modification of the first embodiment of the present invention.

Detailed Description

Hereinafter, embodiments of the present invention will be described based on the drawings.

[ first embodiment ]

(Structure of stator)

Referring to fig. 1 to 19, a structure of a rotating electric machine 100 (stator 20) according to a first embodiment will be described. In the present specification, the "rotation axis direction" refers to the rotation axis direction of rotating electric machine 100 (rotor 10). The "radial direction" refers to a radial direction (radial direction) of the stator 20. The "inner diameter side" refers to the inner diameter side of the stator 20 (or the inner circumferential side of the annular coil 30), and the "outer diameter side" refers to the outer diameter side of the stator 20 (the outer circumferential side of the annular coil 30).

As shown in fig. 1, the rotating electric machine 100 includes a rotor 10. A plurality of permanent magnets 12 are provided in a rotor core 11 of the rotor 10. The plurality of permanent magnets 12 are arranged at substantially equal angular intervals in the circumferential direction.

The rotating electric machine 100 further includes a stator 20 (stator core 21) disposed so as to radially face the outer peripheral surface of the rotor core 11. The stator core 21 includes: an outer diameter side core 21a disposed on the outer diameter side, and an inner diameter side core 21b disposed on the inner diameter side. The outer diameter side core 21a is fitted to the inner diameter side core 21b, thereby forming the stator core 21 having a plurality of (48 in the first embodiment) slots 22 (closed slots). Further, a plurality of teeth 23 are provided so as to sandwich the slot 22.

As shown in fig. 2, the stator 20 includes a plurality of (one for each of 8) coils 30 disposed in the stator core 21. The coil 30 includes a single first coil 30a formed of a single-layer lap-wound coil in which the slot housing portion 31a is disposed on the outer diameter side of the slot 22. The coil 30 includes a single second coil 30b formed of a single-layer lap-wound coil in which the slot housing portion 31b is disposed on the inner diameter side of the slot 22. The coil 30 includes a plurality of (6 in the first embodiment) third coils 30c each including a double-layer lap-wound coil in which one slot housing portion 31c in the circumferential direction is disposed on the outer diameter side of the slot 22 and the other slot housing portion 31c in the circumferential direction is disposed on the inner diameter side of the slot 22. In addition, fig. 2 illustrates only the 1-phase coil 30 among the three-phase coils 30. The first coil 30a, the second coil 30b, and the third coil 30c are examples of the "coil" in the claims.

As shown in fig. 3, the first coil 30a includes a slot housing portion 31a, a coil end portion 32a protruding from an end surface 21c (see fig. 1) of the stator core 21 in the rotation axis direction, and a lead portion 33 a. The first coil 30a includes a first inner coil portion 34a disposed on the inner side and a first outer coil portion 35a disposed on the outer side.

As shown in fig. 3, the second coil 30b includes a slot housing portion 31b, a coil end portion 32b, and a lead portion 33b, as in the first coil 30 a. The second coil 30b includes a second inner coil portion 34b disposed on the inner side and a second outer coil portion 35b disposed on the outer side.

As shown in fig. 4, the third coil 30c includes a slot housing portion 31c, a coil end portion 32c, and a lead portion 33 c. The third coil 30c includes a third coil portion 34c disposed on one side in the circumferential direction and a third coil portion 35c disposed on the other side in the circumferential direction. Also, the third coil portion 34c is connected in series with the third coil portion 35 c.

The first coil 30a, the second coil 30b, and the third coil 30c are connected in parallel with each other. Also, the three-phase coil 30 is Y-connected.

(coil construction)

Next, a detailed structure of the coil 30 will be described with reference to fig. 5. Fig. 5 shows a state before molding (before deformation) of the coil 30 described later. In addition, fig. 5 shows a first inner coil portion 34a, a first outer coil portion 35a, a second inner coil portion 34b, a second outer coil portion 35b, a third coil portion 34c or a third coil portion 35c of the first coil 30a, which is formed by winding coils overlapped by a single layer.

The coil 30 includes a slot housing portion 31 housed in the slot 22 of the stator core 21, a coil end portion 32 protruding from the end surface 21c of the stator core 21 in the rotation axis direction, and a lead portion 33 drawn out to the outside of the stator core 21. The lead portions 33 are one end portions and the other end portions of the conductor wires 40 constituting the coil 30. The lead portion 33 functions as a power line for connection to an external circuit such as a power supply, a neutral line for connection to a connection point (hereinafter referred to as a neutral point) of the other phase coil 30, and the like.

The coil 30 is wound in a state where the conductor wire 40 is laminated from the inner diameter side to the outer diameter side. The conductor line 40 is formed of, for example, a round wire. The lead portion 331 of the coil 30 disposed on the inner diameter side (innermost diameter side) is connected to the power supply side. The lead portion 332 of the coil 30 disposed on the outer diameter side (outermost diameter side) is connected to the neutral point.

As shown in fig. 5 and 6, an annular insulating member 50 (insulating sheet 51) is provided, and the insulating member 50 is provided so as to cover the slot-housed portions 31 and the coil ends 32 of the coil 30 in a substantially U-shape (substantially U-shaped in cross section) from the inner diameter side (inner circumferential side) to the outer diameter side (outer circumferential side) of the coil 30. In the first embodiment, the insulating sheet 51 includes the folded-back portion 52, and the folded-back portion 52 is provided in a portion corresponding to the bent portion of the coil 30, and is formed by folding back (folding) the insulating sheet 51 in a stacked manner a plurality of times so as to follow deformation during the forming process of the coil 30. Specifically, the folded-back portions 52 are provided at portions (folded-back portions 52a to 52d) corresponding to the vicinity of the boundary between the slot-housed portion 31 and the coil end portion 32 and at portions (folded-back portions 52e to 52h) corresponding to the vicinity of the top 321 of the coil end portion 32. The insulating sheet 51 is an example of the "first insulating sheet" and the "insulating member main body" in the claims.

In the first embodiment, as shown in fig. 7 to 9, the folded portion 52 is folded back so that the portion corresponding to the substantially U-shaped bottom portion 521 is stacked and folded back in an S-shaped cross section. Further, the portions of the folded-back portion 52 corresponding to the substantially U-shaped side portions 522 are overlapped with each other so that the portions are deformed to follow the deformation of the coil 30 during the molding process. In fig. 7 and 8, the cross section of the bottom 521 is shown by a solid line in order to clarify the shape of the bottom 521. The portion corresponding to the bottom 521 is folded back 2 times by laminating the insulating sheet 51 in an S-shaped cross section. That is, the insulating sheet 51 is overlapped by 3 layers in the portion corresponding to the bottom 521.

In a state in which the insulating sheet 51 is linearly folded before being attached to the bobbin 60 (see fig. 13) described later, the portions corresponding to the side portions 522 are folded back so as to be stacked in a S-shaped cross section, as in the portions corresponding to the bottom portions 521. Then, the insulating sheet 51 is attached to a bobbin 60 (described later) and is in a ring-like state (see fig. 5), whereby the portion where the insulating sheet 51 is laminated (folded) is opened (unfolded) in a fan-like shape. That is, the portion corresponding to the side portion 522 is opened in a fan shape with the portion on the bottom 521 side as the center. That is, the opening degree of the bottom 521 side of the side portion 522 is relatively small, and tends to be opposite to the bottom 521 of the side portion 522, and the opening degree gradually increases. In addition, the insulating sheet 51 is overlapped by 3 or 2 layers at a portion corresponding to the side portion 522. In addition, the side portion 522 may be partially in a 1-layer state.

In the first embodiment, a plurality of portions of the folded-back portion 52 corresponding to the bottom portion 521 having an S-shaped cross section are provided so as to be continuous in the circumferential direction (along the curved portion of the coil 30) at the portion corresponding to the curved portion of the coil 30. Specifically, as shown in fig. 7, three folded portions 52a to 52d are provided in succession in the circumferential direction at portions corresponding to the bottom portions 521 having the S-shaped cross section of the folded portions 52. As shown in fig. 8, in each of the folded-back portions 52e to 52h, 2 folded-back portions 52 are provided so as to be continuous in the circumferential direction at portions corresponding to the bottom portions 521 having the S-shaped cross section. The number of portions of the folded-back portion 52 corresponding to the substantially U-shaped bottom portion 521 increases or decreases depending on the length of the portion where the folded-back portion 52 is provided (the portion where the coil 30 is bent).

In the first embodiment, the portions of the laminated insulating sheets 51 that form the substantially U-shaped bottom portions 521 at the folded-back portions 52 are fixed to each other. Specifically, the substantially central portion 523 (see fig. 9) of the substantially U-shaped bottom portion 521 (about half of the width direction of the bottom portion 521) is fixed by, for example, ultrasonic welding, hot pressing, adhesive application, or a combination thereof. That is, the portions of the 3-layer insulation sheet 51 constituting the substantially U-shaped bottom 521 are fixed to each other.

In addition, in the first embodiment, as shown in fig. 5, the insulation sheet 51 includes the slot-housed-portion covering portion 53 that covers the slot housed portion 31 of the coil 30, and the coil-end-portion covering portion 54 that covers the coil end 32. Also, the slot-housed-portion covering portion 53 is formed integrally with the coil-end-portion covering portion 54. Specifically, as will be described later, the pair of coil end portions 32 and the pair of slot-housed portions 31 of the coil 30 are covered with 1 insulating sheet 51 which is bent into a substantially U-shape and then deformed into a ring shape.

As shown in fig. 6, an end 55 of the opening of the substantially U-shape of the insulating sheet 51 bent into the substantially U-shape protrudes outward from the outermost diameter portion of the coil 30. That is, the conductor lines 40 are stacked in order from the inside to the outside of the insulating sheet 51 bent in a substantially U-shape to such an extent as to reach the opening. As shown in fig. 10, portions of the insulating sheet 51 that protrude to the outer diameter side beyond the outermost diameter portion of the coil 30 are closed after being wound around the coil 30 (conductor wire 40) inside the insulating sheet 51. That is, the portions protruding outward in the radial direction are overlapped and closed so that the conductor wires 40 are not exposed.

In the first embodiment, a plurality of coils 30 (coils 30 of the same phase) are arranged adjacent to each other (see fig. 2). As shown in fig. 10, one slot housing portion 31 and the other slot housing portion 31 of the adjacent coils 30 are configured to be disposed in the same slot 22. The insulating sheet 51 (insulating sheet 51a) covering the slot housing portions 31 arranged on the inner diameter side of the same slot 22 is opened on the inner diameter side of the stator core 21 (end portions 55a are arranged). The insulating sheet 51 (insulating sheet 51b) covering the slot housing 31 disposed on the outer diameter side of the slot 22 is open on the outer diameter side of the stator core 21 (end portion 55b is disposed).

As shown in fig. 2, the slot accommodating portion 31b of the second coil 30b is disposed on the inner diameter side of the same slot 22, and the slot accommodating portion 31a of the first coil 30a is disposed on the outer diameter side. Further, the slot-receiving portion 31c of the third coil 30c provided on one circumferential side is disposed on the inner diameter side of the same slot 22, and the slot-receiving portion 31c of the third coil 30c provided on the other circumferential side is disposed on the outer diameter side. In either case, the insulating sheet 51a covered by the slot housing 31 disposed on the inner diameter side of the slot 22 is opened on the inner diameter side of the stator core 21, and the insulating sheet 51b covered by the slot housing 31 disposed on the outer diameter side of the slot 22 is opened on the outer diameter side of the stator core 21.

(method for producing insulating sheet)

Next, a method for manufacturing the insulating sheet 51 will be described.

First, as shown in fig. 11, an insulating sheet 51 having a substantially rectangular shape is prepared. Next, as shown in fig. 12, the insulating sheet 51 is folded back a plurality of times in the Y direction so as to be stacked in a S-shaped cross section along a line in the X direction (see a broken line in fig. 11), thereby forming a folded-back portion 52. Further, as shown in fig. 12, the insulating sheet 51 is folded back so that a plurality of (2 in the first embodiment) substantially S-shaped bottom portions 521 are continuous in the Y direction at the folded-back portions 52e to 52h of the insulating sheet 51. Further, as shown in fig. 12, the folded portions 52a to 52d of the insulating sheet 51 are formed by folding the insulating sheet 51 so that a plurality of (three in the first embodiment) substantially S-shaped bottom portions 521 are continuous in the Y direction. Further, the insulating sheet 51 is folded back so that the folded-back portion 52 becomes flat. That is, the insulating sheet 51 is folded back so that the thickness of the folded-back portion 52 is reduced.

Next, the vicinity of the substantially central portion 523 of each X-direction of the folded-back portion 52 of the insulating sheet 51 (the vicinity of the substantially central portion 523 of the portion constituting the substantially U-shaped bottom portion 521) is fixed by, for example, ultrasonic welding, hot pressing, adhesive application, or a combination thereof. I.e., the portions where the insulating sheets 51 are laminated are bonded to each other.

Next, as shown in fig. 14, the insulating sheet 51 is bent in the X direction along a line in the Y direction (see the one-dot chain line in fig. 12). Thereby, the insulating sheet 51 is bent so that its cross section becomes substantially U-shaped. Further, as will be described later, the conductor line 40 is wound around the insulating sheet 51 bent in a substantially U-shape, and then the insulating sheet 51 is bent along the line in the Y-direction (see the two-dot chain line in fig. 12) so as to close the substantially U-shaped opening (see fig. 25). Thereby, the conductor line 40 is covered with the insulating sheet 51.

(production and Molding of coil)

Next, the manufacturing and molding of the coil 30 will be explained.

First, as shown in fig. 15, the bobbin 60 is prepared. The bobbin 60 has a shape (e.g., an octagonal shape) corresponding to the shape of the formed coil 30.

Next, as shown in fig. 5, the insulating sheet 51 is disposed on the bobbin 60. The insulating sheet 51 bent into a substantially U-shape is disposed in a ring shape so as to open on the outer diameter side. At this time, since the linear insulating sheet 51 is disposed on the octagonal bobbin 60, the portion (inner diameter side) of the folded portion 52 of the insulating sheet 51 that forms the substantially U-shaped bottom portion 521 is kept in a folded state (S-shaped in cross section), and the outer diameter side is in a state where the folded portion is spread in the circumferential direction. Further, since the portion of the insulating sheet 51 constituting the substantially U-shaped bottom 521 is fixed, the bottom 521 side (inner diameter side) is difficult to be expanded in the circumferential direction (in the direction along the bent portion of the coil 30). The end portions of the annular insulating sheet 51 are fixed to each other by ultrasonic welding or the like.

Next, as shown in fig. 5, the conductor wire 40 is wound in a state of being laminated from the inner diameter side to the outer diameter side. The conductor wire 40 is wound so that the conductor wire 40 does not reach the opening from the inside of the insulating sheet 51 bent in a substantially U-shape (see fig. 5 and 6). Further, portions of the insulating sheet 51 protruding outward from the outermost diameter portion of the coil 30 are closed (see fig. 10).

Next, as shown in fig. 16 and 17, the slot housing 31 on the one side and the slot housing 31 on the other side of the coil 30 around which the conductor wire 40 is wound are twisted in the C direction. Thus, in the insulating sheet 51, the portion corresponding to the slot housing 31 on one side (left side in the drawing) is disposed on the front side (side in the direction of B1) of the drawing with the portion corresponding to the opening of the insulating sheet 51 (closed portion, end portion 55), and the portion corresponding to the slot housing 31 on the other side (right side in the drawing) is disposed on the back side (side in the direction of B2) of the drawing with the portion corresponding to the opening of the insulating sheet 51.

Next, the coil 30 is deformed (bent) along the circumferential bending of the stator core 21. The third coil 30c is deformed such that one of the slot housing portions 31c is disposed on the inner diameter side and the other slot housing portion 31c is disposed on the outer diameter side.

The bent coils 30 are disposed in the slots 22 of the stator core 21. At this time, of the coils 30 arranged in the same slot 22, the insulating sheet 51a (see fig. 10) covering the slot housing 31 arranged on the inner diameter side of the slot 22 is arranged so as to open on the inner diameter side of the stator core 21. The insulating sheet 51b (see fig. 10) covering the slot housing 31 disposed on the outer diameter side of the slot 22 is disposed so as to open on the outer diameter side of the stator core 21.

Finally, as shown in fig. 18 and 19, the coil end 32 of the coil 30 disposed in the slot 22 is formed so as to be bent toward the inner diameter side (the back side of the drawing sheet). At this time, the folded portion 52 in which the insulating sheet 51 is laminated expands (unfolds) following the deformation of the shape of the coil 30, and therefore the insulating sheet 51 is prevented from being damaged.

As shown in fig. 20, in a state where the coils 30 are disposed in the slots 22, the coil ends 32 of adjacent coils 30 overlap each other when viewed from the radial direction of the stator 20. On the coil inner diameter side, which is a high-voltage portion, the insulation sheet 51 of the folded portion 52 (side portion 522) of the insulation sheet 51 is laminated by 3 layers at most. Thus, in a state where the two coil ends 32 overlap each other when viewed in the radial direction of the stator 20, the insulation sheet 51 is disposed between the two coil ends 32 in a maximum of 6 layers (3 layers × 2). In addition, if the folded portion 52 is adjusted so that the folded portion 52 is disposed without a gap, 4 layers (1 layer +3 layers) are disposed at minimum. This enables the coil ends 32 of the adjacent coils 30 to be insulated more reliably.

(Effect of the first embodiment)

In the first embodiment, the following effects can be obtained.

In the first embodiment, as described above, the insulating sheet 51 includes the folded-back portion 52, and the folded-back portion 52 is provided at a portion corresponding to the bent portion of the coil 30 and is formed by folding back the insulating sheet 51a plurality of times so as to be laminated. This deforms to follow the bent portion of the coil 30 during the molding process, and expands (unfolds) the folded portion 52 on which the insulating sheet 51 is laminated, thereby preventing the insulating member 50 from being damaged due to the deformation of the coil 30. As a result, it is possible to prevent the insulating property between the coils 30 from being unable to be ensured due to the breakage of the insulating member 50.

In the first embodiment, as described above, the portions of the folded-back portion 52 corresponding to the bottom 521 of the substantially U-shape are folded back in a stacked manner so as to form an S-shape in cross section, and the portions corresponding to the side portions 522 of the substantially U-shape are configured so that the stacked portions overlap each other. Thus, the folded portion 52 can be unfolded so as to open in a fan shape with the portion of the folded portion 52 corresponding to the substantially U-shaped bottom portion 521 as the center, following the deformation of the coil 30 during the molding process. The folded portion 52 is deformed so that the inner diameter side is folded and the outer diameter side is spread in a fan shape. This makes it easy to form the insulating member 50 into a ring shape. Further, since the insulating sheet 51 is folded back so as to be stacked with the S-shaped cross section, the thickness of the insulating sheet 51 can be reduced, unlike the case where the insulating sheet 51 is folded back in a wave shape (W-shaped).

In the first embodiment, as described above, a plurality of folded portions 52 are provided so that portions corresponding to the bottom portions 521 having an S-shaped cross section are circumferentially continuous with portions corresponding to the bent portions of the coil 30. Accordingly, even when the bent portion of the coil 30 is relatively large (long in the circumferential direction), the insulating sheet 51 (folded portion 52) can be deformed in accordance with the relatively large bent portion of the coil 30.

In the first embodiment, as described above, the folded portions 52 are fixed to each other at the portions of the laminated insulating sheets 51 that constitute the substantially U-shaped bottom portions 521. Thus, the insulating sheets 51 constituting the bottom portion 521 are prevented from being released from the stacked state, and therefore, the folded portion 52 is easily spread so as to be opened in a fan shape with the portion corresponding to the substantially U-shaped bottom portion 521 as the center.

In the first embodiment, as described above, the slot housing cover portions 53 of the insulating sheet 51 are formed integrally with the coil end cover portions 54. This enables the coil 30 to be substantially entirely covered with 1 insulating sheet 51, thereby preventing an increase in the number of components.

In the first embodiment, as described above, one slot housing portion 31 and the other slot housing portion 31 of the adjacent coils 30 are disposed in the same slot 22. Further, the insulating member 50 covering the slot housing portion 31 disposed on the inner diameter side of the same slot 22 is opened on the inner diameter side of the stator core 21, and the other insulating member 50 covering the slot housing portion 31 disposed on the outer diameter side of the slot 22 is opened on the outer diameter side of the stator core. Accordingly, since the openings of the insulating members 50 disposed in the same slot 22 are oriented in different directions, the conductor lines 40 protruding from the openings of the insulating members 50 can be prevented from contacting (short-circuiting) each other.

[ second embodiment ]

The structure of the rotating electric machine 101 (stator 120) according to the second embodiment will be described with reference to fig. 21 to 25. In the rotating electric machine 101 (stator 120) according to the second embodiment, the insulating member 150 includes an insulating sheet 152 provided so as to overlap with the slot housing cover portion 151a of the insulating sheet 151. Further, the insulating sheet 151 is an example of the "first insulating sheet" and the "insulating member main body" of the claims. The insulating sheet 152 is an example of the "second insulating sheet" and the "insulating member main body" in the claims.

As shown in fig. 21, the insulation sheet 151 includes a slot housing cover portion 151a that covers the slot housing 31, and a coil end cover portion 151b that covers the coil end 32, as in the first embodiment described above. As shown in fig. 22, an insulating sheet 152 is provided so as to overlap the insulating sheet 151 on the side corresponding to the inside of the substantially U-shaped slot housing portion covering portion 151 a. That is, the insulating sheet 152 is disposed between the coil 30 and the insulating sheet 151.

As shown in fig. 23, a length L1 of the insulating sheet 152 in the Y direction is substantially the same as a length L2 of the slot housing cover portion 151a in the Y direction. On the other hand, the width W1 of the insulating sheet 152 in the X direction is smaller than the width W2 of the slot-housed-portion covering portion 151a in the X direction. In addition, the insulating sheet 152 is provided with 1 layer.

In the second embodiment, the insulating sheet 152 is made of a material having higher insulation than the insulating sheet 151. Specifically, the insulating sheet 151 is made of, for example, nomex (registered trademark). Further, nomex is a fiber (paper) formed of an aramid polymer. The insulating sheet 152 is made of kapton (registered trademark), for example. Further, kapton is a membrane formed of polyimide.

The insulating sheet 152 is locally welded to the insulating sheet 151 by ultrasonic waves, for example. That is, the insulating sheet 152 is temporarily fixed to the insulating sheet 151. Thereby, unlike the case where the insulating

sheets

151 and 152 composed of different materials are bonded over the entire surfaces, the bending of the insulating

sheets

151 and 152 can be prevented. Here, the insulating member 150 (the insulating sheet 151 and the insulating sheet 152) is bent into a substantially U-shape and then arranged in the slot 22 together with the coil 30. Thus, the insulating member 150 (the insulating sheet 151 and the insulating sheet 152) is sandwiched between the coil 30 and the slot 22, and therefore, even when the insulating sheet 152 is temporarily fixed to the insulating sheet 151, the insulating sheet 152 is not separated from the insulating sheet 151.

The other structure of the second embodiment is the same as that of the first embodiment.

(method for producing insulating sheet)

Next, a method for manufacturing the insulating member 150 will be described.

First, as shown in fig. 23, an insulating sheet 151 having a substantially rectangular shape is prepared. Next, the insulating sheet 152 is partially welded to the insulating sheet 151 by, for example, ultrasonic waves. For example, the edge portions of the insulating sheet 152 on the X direction side (the X1 direction side, the X2 direction side) are welded in the Y direction. Further, the insulating member 150 is folded back a plurality of times in the Y direction to thereby form a folded-back portion 153.

Next, the vicinity of the substantially central portion of the folded-back portion 153 constituting the substantially U-shaped bottom portion is fixed by, for example, ultrasonic welding, hot pressing, adhesive application, or a combination thereof.

Next, as shown in fig. 24, the insulating member 150 (insulating sheet 151, insulating sheet 152) is bent in the X direction. Thereby, the insulating sheet 51 is bent so that its cross section becomes substantially U-shaped. Then, the insulating member 150 is disposed on the bobbin 60 so as to extend along the bobbin 60 (see fig. 15) (in a ring shape). Then, the conductor wire 40 is wound around the insulating member 150 disposed on the bobbin 60. Finally, as shown in fig. 25, the insulating sheet 151 and the insulating sheet 152 are bent so as to cover the conductor line 40 (coil 30).

(Effect of the second embodiment)

In the second embodiment, the following effects can be obtained.

In the second embodiment, as described above, the insulating member 150 includes the insulating sheet 152 provided so as to overlap the insulating sheet 151. Thus, the slot-housed portions 31 of the coil 30 are covered with the two-layer insulating members (the insulating sheets 151 and 152), and therefore, the insulating properties of the slot-housed portions 31 of the coil 30 can be improved.

In the second embodiment, as described above, the insulating sheet 152 is formed of a material having higher insulation than the insulating sheet 151. This can reliably improve the insulation of the slot housing 31 of the coil 30.

[ third embodiment ]

The structure of the rotating electric machine 102 (stator 220) according to the third embodiment will be described with reference to fig. 26 to 28. In the rotary electric machine 102 (stator 220) of the third embodiment, the width W11 of the coil end covering portion 251b of the insulating member 250 is larger than the width W12 of the slot-housed portion covering portion 251 a.

As shown in fig. 26, the insulating sheet 251 includes a slot housing cover portion 251a that covers the slot housing 31, and a coil end cover portion 251b that covers the coil end 32, as in the second embodiment described above. Further, a width W11 (see fig. 27) of the coil end covering portion 251b in the direction orthogonal to the direction in which the insulating sheet 251 extends is larger than a width W12 (see fig. 27) of the slot housing portion covering portion 251a in the direction orthogonal to the direction in which the insulating sheet 251 extends. In addition, as shown in fig. 27, the coil end cover portions 251b protrude from the slot housing portion cover portions 251a in the X direction on both sides of the X1 direction side and the X2 direction side. That is, in a state where the insulating member 250 is bent in a substantially U-shape (see fig. 26), the coil end covering portions 251b protrude from the slot housing portion covering portions 251a on both side portions of the substantially U-shape. The insulating sheet 251 is an example of the "first insulating sheet" and the "insulating member main body" in the claims.

Here, when the slot housing 31 of the coil 30 is twisted (see fig. 16), the conductor wire 40 may move in the longitudinal direction of the coil 30. In this case, the width W11 of the coil end covering portion 251b in the direction orthogonal to the direction in which the insulating sheet 251 extends is larger than the width W12 of the slot-housed portion covering portion 251a in the direction orthogonal to the direction in which the insulating sheet 251 extends, and therefore the conductor line 40 can also be prevented from protruding from the coil end covering portion 251 b.

In the third embodiment, the width W11 of the coil end covering portion 251b in the direction perpendicular to the direction in which the insulating sheet 251 extends is configured to be gradually increased from the side connected to the slot housing portion 251a toward the direction away from the slot housing portion 251 a. Specifically, the coil end covering portion 251b is formed to extend in the direction in which the insulating sheet 251 extends, with the width W11 being increased in a tapered shape from the side connected to the slot housing portion 251a and then the width W11 being constant. The tapered coil end covering portion 251b is a portion of the insulating member 250 corresponding to folded portions 253a to 253d, which will be described later.

In addition, as in the second embodiment, the insulating sheet 251 is provided with folded portions 253(253a to 253h) folded back so that the insulating sheet 251 is laminated at portions corresponding to the bent portions of the coil 30. In addition, as in the second embodiment, an insulating sheet 252 is provided in the slot housing portion covering portion 251 a. The insulating sheet 252 is an example of the "second insulating sheet" and the "insulating member main body" in the claims.

(Effect of the third embodiment)

In the third embodiment, the following effects can be obtained.

In the third embodiment, the width W11 of the coil end covering portion 251b in the direction orthogonal to the direction in which the insulating sheet 251 extends is made larger than the width W12 of the slot-housed portion covering portion 251a in the direction orthogonal to the direction in which the insulating sheet 251 extends. Accordingly, even when the conductor wire 40 moves in the longitudinal direction of the coil 30 when the slot housing 31 of the coil 30 is twisted (see fig. 16), the conductor wire 40 can be prevented from protruding from the coil end covering portion 251 b.

In the third embodiment, as described above, the width W11 of the coil end covering portion 251b in the direction perpendicular to the direction in which the insulating sheet 251 extends is gradually increased from the side connected to the slot housing portion 251a in the direction away from the slot housing portion 251 a. Thus, when the insulating member 250 is deformed into a ring shape, the folded portions 253a to 253h can be easily deformed into a fan shape. In addition, when the insulating member 250 is deformed into a ring shape, the width of the insulating member 250 gradually increases from the slot housing portion covering portion 251a to the coil end covering portion 251b, and therefore the outer shape of the ring-shaped insulating member 250 can be made to follow the shape of the bent portion of the coil 30.

[ modified examples ]

It should be noted that the entire contents of the embodiments disclosed herein are merely exemplary and not intended to be limiting. The scope of the present invention is defined by the appended claims rather than the description of the embodiments above, and includes all modifications (variations) within the meaning and range equivalent to the claims.

For example, in the first to third embodiments, the folded-back portions are provided at the portions corresponding to the vicinity of the boundary between the slot-housed portion and the coil end portion and the portions corresponding to the vicinity of the top of the coil end portion, but the present invention is not limited to this. For example, the folded-back portion may be provided in a portion other than a portion corresponding to the vicinity of the boundary between the slot-housed portion and the coil end portion and a portion corresponding to the vicinity of the top of the coil end portion.

In the first to third embodiments, the insulating sheet is provided so as to cover the coil from the inner diameter side toward the outer diameter side in a substantially U-shape. For example, the insulating sheet may be covered in a substantially U-shape from the outer diameter side to the inner diameter side of the coil.

In the first to third embodiments, the portions of the folded-back portions corresponding to the bottom portions of the approximate U-shape are folded back in a stacked manner so as to form an S-shape (3 layers) in cross section. For example, the portion of the folded portion corresponding to the bottom portion of the substantially U-shape may be folded back so as to be stacked in 4 layers or more.

In the first to third embodiments, the example is shown in which a plurality of portions of the folded-back portion corresponding to the bottom portion having the S-shaped cross section are provided continuously in the circumferential direction at the portion corresponding to the bent portion of the coil, but the present invention is not limited to this. For example, when the bent portion of the coil is small, only one portion of the folded-back portion corresponding to the bottom portion of the substantially U-shape may be provided.

In the first to third embodiments, the coil is covered with one insulating member, but the present invention is not limited to this. For example, as shown in a modification of fig. 29, the insulating member 80 (insulating

members

80a and 80b) divided into 2 pieces may be prepared, and the insulating member 80 divided into 2 pieces may be disposed in the coil (bobbin). Further, in the insulating member 80, the slot-housed-portion covering portion 81a is formed integrally with the coil-end covering portion 81 b. In addition, the insulating

members

80a and 80b are provided with folded portions 82, respectively.

In the first to third embodiments, the first and second coil portions formed of the single-layer lap-wound coil are provided, but the present invention is not limited thereto. For example, the coil may be constituted by only a third coil formed by double-layer lap winding coils.

In the first to third embodiments, the example in which 48 slots are provided in the stator core is shown, but the present invention is not limited to this. In the present invention, the stator core may be provided with a number of slots other than 48.

In the second embodiment, the example in which 1 insulating sheet made of kapton is provided so as to overlap with the insulating sheet made of nomex is described, but the present invention is not limited to this. For example, an insulating sheet made of kapton may be provided in two or more layers so as to overlap with the insulating sheet made of nomex.

Description of reference numerals: 20. 120, 220 … stator; 21 … stator core; 21c … end face; 22 … slot; 30 … coil; 30a … first coil (coil); 30b … second coil (coil); 30c … third coil (coil); 31. 31a, 31b, 31c … slot receiving portions; 32. 32a, 32b, 32c … coil ends; 50. 80, 80a, 80b, 150, 250 … insulating members; 51. 151, 251 … insulating sheet (first insulating sheet, insulating member main body); 52. folding parts 52a to 52h, 82, 153, 253a to 253h …; 53, 81a, 151a, 251a … slot receiving portion covering portion; 54. 81b, 151b, 251b … coil end covering portions; 152. 252 … insulating sheet (second insulating sheet); 521 … bottom; 522 … bottom

Claims

1. An insulating member, wherein,

the coil is provided with an insulating member main body including a first insulating sheet provided in a ring shape so as to cover a coil, the coil including: a slot housing part housed in a slot of a stator core, and a coil end part protruding from an end face of the stator core in a rotation axis direction,

the first insulating sheet includes a folded-back portion provided at a portion corresponding to the bent portion of the coil and folded back a plurality of times in a manner that the first insulating sheet is laminated,

the first insulating sheet is provided so as to cover in an approximately U-shape from an inner diameter side toward an outer diameter side of the coil,

the folded-back portion is folded back so that a portion corresponding to the bottom portion of the approximate U shape is S-shaped in cross section, and the laminated portions of the portions corresponding to the side portions of the approximate U shape are overlapped with each other,

in the folded-back portion, portions of the first insulating sheets laminated in an S-shaped cross section constituting the substantially U-shaped bottom portion are fixed to each other,

the folded portion is unfolded so as to be opened in a fan shape with a portion of the folded portion corresponding to the bottom portion of the approximate U shape as a center.

2. The insulating member according to claim 1,

the folded portion is provided in a plurality of portions corresponding to the bottom portion having an S-shaped cross section, and the portions corresponding to the bent portions of the coil are arranged so as to be continuous in the circumferential direction.

3. The insulating member according to claim 1 or 2, wherein,

the first insulating sheet includes: a slot-housed portion covering portion that covers the slot-housed portion, and a coil-end covering portion that covers the coil end,

the slot-receiving-portion covering portion is integrally formed with the coil-end covering portion.

4. The insulating member according to claim 1 or 2, wherein,

the insulating member main body further includes a second insulating sheet provided in such a manner as to overlap with the first insulating sheet.

5. The insulating member according to claim 4,

the second insulating sheet is composed of a material having higher insulation than the first insulating sheet.

6. The insulating member according to claim 1 or 2, wherein,

the width of the coil end covering portion in a direction orthogonal to a direction in which the first insulating sheet extends is larger than the width of the slot receiving portion covering portion in a direction orthogonal to a direction in which the first insulating sheet extends.

7. The insulating member according to claim 6,

a width of the coil end covering portion in a direction orthogonal to a direction in which the first insulating sheet extends is configured to: and gradually increases from a side connected with the slot housing portion covering portion toward a direction of being separated from the slot housing portion covering portion.

8. A stator is provided with:

a stator core;

a coil disposed on the stator core, the coil including: a slot housing portion housed in a slot of the stator core, and a coil end portion protruding from an end surface of the stator core in a rotation axis direction; and

an insulating member provided in a ring shape so as to cover the coil,

the insulating member includes a folded portion provided at a portion corresponding to the bent portion of the coil and folded a plurality of times in a manner that the insulating member is laminated,

the insulating member is provided so as to cover the coil from the inner diameter side toward the outer diameter side thereof in an approximately U-shape,

in the folded-back portion, portions of the insulating members which constitute the substantially U-shaped bottom portion and are stacked in an S-shaped cross section are fixed to each other,

9. The stator according to claim 8,

the coils are arranged in a plurality in an adjacent manner,

and is constituted such that: one of the slot-receiving portions of the adjacent coils and the other slot-receiving portion are disposed in the same slot,

one of the insulating members covering the slot-receiving portion disposed on the inner diameter side of the same slot is closed on the inner diameter side of the stator core, and the other insulating member covering the slot-receiving portion disposed on the outer diameter side of the slot is closed on the outer diameter side of the stator core.